Casting vs injection molding—which method works better?

Casting Vs Injection Molding—Which Method Works Better?

Maybe it comes down to how much rough use they see?

That’s a good point, and I think you’re onto something with the “rough use” factor. In my experience, the context really does matter. For example, in commercial projects where we spec hardware for public restrooms or high-traffic corridors, cast metal almost always outlasts plastic—regardless of whether the plastic is injection-molded or not. The rigidity and density of cast metal just seem to shrug off abuse that would leave plastic components flexed or even cracked.

But I’ve also seen some surprisingly tough injection-molded handles, especially when the design incorporates internal ribs or thicker cross-sections. The recycled stuff can be hit or miss, though. Sometimes it’s just not as consistent in terms of strength or finish. Have you noticed any difference between virgin and recycled plastics in your installs?

One thing I’ve run into: cast metal handles can get loose at the mounting points over time, especially if the fasteners aren’t up to par or the substrate is soft. That’s less about the casting itself and more about the whole assembly, but it’s bitten me a couple times on older renovations. With injection-molded parts, it’s usually the body that fails first, not the mounting.

I’m curious—are you seeing the warping and bending mostly on longer handles or thinner profiles? I’ve found that short, chunky injection-molded pulls hold up better than the longer, slender ones. Maybe it’s a geometry thing as much as a material thing.

Anyway, I wouldn’t say there’s a universal answer here. For pure durability in a rental or public setting, I still lean toward cast metal, but I’ll admit the gap is closing as plastics improve. If cost or weight is a big concern, injection molding starts to look a lot more attractive... but yeah, nothing beats the feel of solid metal when you’re dealing with heavy use.

I get where you’re coming from on cast metal being tougher, but I’ve actually had a few cast handles snap clean off at the mounting point—usually when the casting had some air pockets or wasn’t finished right.

“cast metal handles can get loose at the mounting points over time, especially if the fasteners aren’t up to par or the substrate is soft.”

Title: Casting vs Injection Molding—Which Method Works Better?

I’ve run into the same thing with cast handles cracking at the base, especially on older doors where the fit isn’t perfect. It’s frustrating when you expect metal to outlast plastic, but that’s not always how it goes. I’m starting to think a sturdy injection-molded pull makes more sense for high-traffic spots. The durability’s surprised me, honestly… guess it really does come down to the quality, not just the material.

- Gotta admit, I used to be all about cast metal for “forever” hardware, but those cracks are a dealbreaker.
- Injection molding’s not perfect, but it’s way less wasteful if you’re using recycled plastics.
- Plus, if you ever need to swap out a handle, it’s lighter and easier on the hands—bonus for accessibility.
- Still, I wish more companies would offer bio-based or recycled options... feels like we’re overdue for greener choices.

Casting Vs Injection Molding—Which Method Works Better?

I totally get the appeal of cast metal—there’s something about that solid, old-school feel that just seems like it’ll last forever. But yeah, those hairline cracks are a nightmare. I had a cast metal door handle in my last apartment and it looked amazing... until it didn’t. One winter, it just split right down the middle. Not fun.

I’m actually loving the lighter injection-molded stuff in my new place. Swapping out cabinet pulls was way less of a hassle, and my hands didn’t ache after. Plus, I’ve seen some really creative designs with recycled plastics—like, colors and textures you just can’t get with metal. Still, I wish there were more options that didn’t feel so... plasticky? Some of the bio-based handles I’ve seen online look cool but I haven’t found any in stores near me yet.

Honestly, if companies started making more eco-friendly hardware that actually looked good, I’d be all over it. Feels like we’re stuck choosing between “forever” metal that might crack or plastic that’s not always green. There’s gotta be a better middle ground, right?